EMW SLURRY PUMP - RUBBER - A.R. Wilfley and Sons, Inc.

Transcription

Rev 3
August 2014
A.R. Wilfley and Sons, Inc.
EMW® SLURRY PUMP - RUBBER
Installation, Operation, Maintenance and Storage Manual
VISIT US AT
WWW
.WILFLEY.COM
7350 E. Progress Place, Englewood, CO 80111 USA • Toll Free: 1-800-525-9930 • Phone: +1 (303) 779-1777 • Fax: +1 (303) 779-1277
www.wilfley.com • [email protected]
Rev 3
August 2014
TABLE OF CONTENTS
Forward .............................................................................2
1.0 Introduction .................................................................3
2.0 Safety Considerations .................................................3
2.1 Safety Tips ............................................................... 4
2.1.1 Operator / User ................................................. 4
2.1.2 Maintenance, Inspection, and Installation ......... 4
2.2 Unauthorized Modification and Manufacture of
Spare Parts .................................................................... 5
2.3 Unauthorized Operation ........................................... 5
3.0 Transport and Storage ................................................5
3.1 Transport Requirements .......................................... 5
3.2 Handling .................................................................. 5
3.2.1 Bare Pump ........................................................ 5
3.2.2 Pump and Overhead Assembly......................... 5
3.3 Storage Requirements ............................................. 6
3.3.1 Short Term Pump Storage ................................ 6
3.3.2 Long Term Pump Storage ................................. 6
3.3.3 Parts Storage .................................................... 6
3.3.4 Motor and Seal Storage .................................... 6
4.0 Installation ...................................................................6
4.1 Inspection upon Arrival ............................................ 6
4.2 Choosing Pump Location ......................................... 6
4.3 Foundation ............................................................... 7
4.4 Alignment................................................................. 7
4.5 Piping....................................................................... 7
4.6 Discharge Piping...................................................... 7
4.7 Suction Piping .......................................................... 7
4.8 Packing / Seal Flush Piping ..................................... 7
4.9 Piping Note .............................................................. 8
4.10 Installation and Alignment ...................................... 8
5.0 Coupling and V-Belt Guard .........................................8
6.0 Commissioning, Start-Up and Shutdown Instructions .9
6.1 Commissioning ........................................................ 9
6.2 Start-Up ................................................................... 9
6.3 Shutdown ................................................................. 9
7.0 General Service and Maintenance ..............................9
7.1 Periodic Maintenance .............................................. 9
7.1.1 Flow, Pressure, and Temperature Monitoring ... 9
7.1.2 Visual Inspections ........................................... 10
7.1.3 Pump Wash Down .......................................... 10
7.2 Lubrication ............................................................. 10
7.2.1 Grease Lubrication .......................................... 10
7.2.2 Initial Bearing Grease Fill ................................ 10
7.2.3 Grease Lubrication Interval ............................. 10
7.2.4 Oil Lubrication ................................................. 10
7.2.5 Oil Capacities .................................................. 10
7.3 Wear Adjustment ................................................... 11
7.4 General Servicing Attributes .................................. 11
7.5 Impeller Replacement............................................ 11
7.6 Designation............................................................ 12
7.7 Drainage / Disposal ............................................... 12
8.0 General Instructions for Ordering Parts ..................... 12
8.1 Design Details ....................................................... 12
8.1.1 Pump Casing .................................................. 12
8.1.2 Impeller ........................................................... 12
8.1.3 Bearing Cartridge ............................................ 12
8.1.4 Sealing System ............................................... 12
8.1.4.1 Expeller with Packing Seal ....................... 12
8.1.4.2 Packing Seal ............................................ 13
8.1.4.3 Mechanical Seal ....................................... 13
8.1.4.4 Diaphragm Seal with Expeller .................. 13
8.1.4.4 Dynamic Seal with Expeller ...................... 13
9.0 General Assembly Information .................................. 13
9.1 Specialized Tools for Assembly and Disassembly. 14
9.1.1 Impeller Tool ................................................... 14
9.1.2 Shaft Wrench .................................................. 14
9.1.3 Shaft Handling Tool......................................... 14
9.1.4 Radial Bearing Alignment Tool ........................ 14
10.0 General Pump Assembly Sequence ....................... 15
10.1 Power End Assembly .......................................... 15
10.2 Wet End Assembly .............................................. 23
10.2.1 Expeller with Packing .................................... 23
10.2.2 Packing ......................................................... 27
10.2.3 Mechanical Seal ............................................ 31
10.4 Case (Suction Half) Assembly ............................. 35
10.4.1 Pumps Size 150 (6x4) and Smaller ............... 35
10.4.2 Pumps Size 200 (8x6) and Larger ................ 35
10.5 Seal Guard Assembly .......................................... 37
10.6 Setting Clearances .............................................. 38
11.0 General Specifications ............................................ 39
11.1 Forces and Moments ........................................... 39
11.2 Noise Characteristics ........................................... 40
11.3 Accessories ......................................................... 40
11.4 Dimensions and Weights ..................................... 40
11.5 Torque Values ..................................................... 40
12.0 TROUBLESHOOTING ............................................ 41
Appendix 1 ...................................................................... 42
Page 1
Rev 3
August 2014
Forward
This manual provides instructions for the Installation, Operation, Maintenance, and Storage of the Wilfley
EMW Standard Pump. The standard assembly is a grease lube pump with an expeller seal. This manual covers
the standard product in addition to common options that are available. Supplemental instructions are supplied for
special options. This manual must be read and understood before installation and start-up.
The design, materials, and workmanship incorporated in the construction of Wilfley EMW pumps makes them
capable of providing trouble-free service. The life and satisfactory service of any mechanical unit is enhanced
and extended by correct application, proper installation, periodic inspection, condition monitoring, and careful
maintenance. This instruction manual was prepared to assist operators in understanding the construction and the
correct methods of installation, operation, maintenance, and storage of these pumps.
A.R. Wilfley & Sons, Inc. (ARW) and Ensival-Moret shall not be liable for damage or delays caused by
a failure to observe the instructions for installation, operation, maintenance, and storage contained in this
manual.
Warranty is valid only when genuine EMW parts are used. Contact your local EMW representative for
basic warranty information and before making any changes.
Use of the equipment on a service other than stated in the order could nullify the warranty, unless written
approval is obtained in advance from ARW.
To assure proper installation, supervision from an authorized manufacturer’s representative is recommended.
Additional manuals can be obtained by contacting your local EMW representative.
THIS MANUAL EXPLAINS
•
•
•
•
•
•
•
•
•
•
Proper Storage
Proper Installation
Start-up Procedures
Shutdown Procedures
Operating Procedures
Preventive Maintenance
Pump Overhaul
Spare or Repair Parts
Pump Assembly
Troubleshooting
Page 2
Rev 3
August 2014
1.0 Introduction
This manual contains instructions and guidelines for
the installation, operation, maintenance, and storage
of the EMW Standard Pumps.
There are many factors affecting the successful
installation, operation, and maintenance of a pump.
There are variations in these factors per individual
pump; therefore, the information contained herein
shall only be used as a general guideline. If detailed
questions or problems arise, contact the Wilfley
Sales Office, Distributors, or Representatives.
It is important that this manual be read prior to
installation or start-up on the pump to understand
the safety, proper performance of the pump, and
maximum Mean Time Between Planned
Maintenance (MTBPM).
2.0 Safety Considerations
Centrifugal pumps can be dangerous if used
improperly. Any misuses may result in a pump that
does not function properly. A pump that does not
function properly may be a hazard and could cause
damage or injury.
For maximum safety and reliability, use only factory
supplied parts and follow all maintenance and
operating recommendations and instructions.
The following list is meant to be provided only as a
guide for some of the common types of misuse that
can damage a pump and/or cause injury and will
void any and all warranties.
7. Do not operate a pump that is vibrating,
surging, or making an abnormal noise.
8. Do not work on a pump unless the drive
system is locked out and the pump is
disconnected from the drive system.
9. Do not connect the pump to the drive system
without verifying that the drive system is
running in the correct direction.
10. Do not rely on the factory’s alignment of the
pump and the drive system. Alignment may
have changed during shipment.
11. Do not change the pumping conditions or
installation of an EMW pump without
consulting ARW first to ascertain if the pump is
capable of handling the new conditions and/or
fluid.
12. Do not insert a cold liquid in or on a hot pump
or a hot liquid in or on a cold pump.
13. Do not hit a pump with any object.
14. Do not use worn or faulty parts.
15. Do not stick hands, arms, legs, or any other
object into the discharge, suction, or any other
opening of a pump.
16. Do not weld attachments to the pump.
17. Do not apply external heat to the pump.
18. Do not lift the pump by only its case.
1. Do not run a pump with the discharge valve
closed.
19. Do not examine a pump without using proper
eye, face, and toe protection.
2. Do not run a pump in the reverse direction.
20. Some materials deteriorate with time. If your
pump has been out of service for more than 3
months, please contact ARW for information
concerning its suitability for service.
3. Do not start a pump that is “wind-milling” in the
reverse direction due to fluid flowing back
down the discharge pipe.
4. Do not continue to operate a pump when there
are indications that something is rubbing,
binding, or knocking.
5. Do not continue to run a pump that gives an
indication of overheating.
The EMW pump has been designed and
manufactured for safe operation. In order to ensure
safe operation, it is very important that this manual
be read in its entirety prior to installation or operation
of the pump. ARW shall not be liable for physical
injury, damage, or delays caused by a failure to
observe these instructions.
6. Do not operate a pump with any equipment
guard removed. Make sure all equipment
guards are correctly installed.
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August 2014
Every pump has the potential to be dangerous due
to the following factors:
•
Parts are rotating at high speeds.
•
High pressures may be present.
•
High temperatures may be present.
•
Highly corrosive and/or toxic chemicals may
be present.
Paying close attention to safety is always extremely
important; however, there are often situations that
require special attention which are indicated
throughout this book by the following symbols:
!
DANGER
DANGER – Immediate hazards that WILL result in
severe personal injury or death.
•
Wear steel toe shoes for protection when
handling parts, heavy tools, etc.
•
Wear other personal protective equipment to
protect against hazardous/toxic fluids.
•
Any hot or cold components that could pose a
hazard must be equipped with a guard by the
operator.
•
Guards that are fitted to prevent accidental
contact with moving parts must not be
removed while the machine is operating.
•
Leakages of hazardous material must be
handled in a manner which avoids any danger
to persons and the environment. Pertinent
legal provisions must be followed.
•
Electrical hazards must be eliminated.
2.1.2 Maintenance, Inspection, and
Installation
•
The operator is responsible for ensuring that
all maintenance, inspection, and installation
work is performed by authorized and qualified
personnel who understand the manual.
•
Work on the machine must only occur at
standstill. The shutdown procedure described
in Shutdown (Section 6) for taking the
machine out of service must be followed.
•
All safety/protective devices must be reinstalled and/or reactivated immediately
following completion of the work.
•
Please observe all instructions described in
Commissioning (Section 6) before returning
the machine to service.
•
Always lockout or tag out power.
•
Ensure pump is isolated from system and
pressure is relieved before disassembling
pump, removing plugs, or disconnecting
piping.
Wear insulated work gloves when handling hot
bearings or using bearing heater.
•
Use proper lifting and supporting equipment to
prevent serious injury.
Wear heavy work gloves when handling parts
with sharp edges, especially impellers.
•
Observe proper decontamination procedures.
•
Know and follow company safety regulations.
!
WARNING
WARNING – Hazards or unsafe practices that
COULD result in severe personal injury or death.
!
CAUTION
CAUTION - Hazards or unsafe practices that
COULD result in minor personal injury or product
or property damage.
NOTE: Always coordinate repair activity with
operations personnel and follow all plant safety
requirements and applicable safety and health
Laws/Regulations.
2.1 Safety Tips
2.1.1 Operator / User
•
•
•
Wear safety glasses (with side shields) for eye
protection, especially in machine shop areas.
Page 4
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August 2014
•
Never apply heat to remove impeller.
•
Observe all cautions and warnings highlighted
in pump instruction manual.
2.2 Unauthorized Modification and
Manufacture of Spare Parts
Modifications of the pump and/or pump parts are
only permitted with approval from the manufacturer.
Original spare parts and accessories authorized by
the manufacturer ensure safety. The use of other
parts can void any liability of the manufacturer for
damage or warranty.
!
WARNING
Care should be taken to ensure all lifting lines
are properly installed to prevent a load shift. A
load shift may result in injury, death, or property
damage.
Do not lift pump using the bearing cartridge or
shaft as a hoist point.
Before lifting the equipment refer to the pump data
sheet for the complete assembly weight.
3.2.1 Bare Pump
2.3 Unauthorized Operation
Any warranty of the operating reliability and safety of
the pump/unit supplied is only valid if the machine is
operated in accordance with its designated use. The
limits stated in the data sheet must not be exceeded
under any circumstances.
Attach slings on pump case and pedestal. The
slings form three points for lifting as shown on the
next page. The sling lengths should be adjusted to
balance the load before attaching the lifting hook.
3.0 Transport and Storage
Following proper transport and storage practices
prevents damage to pumping units.
3.1 Transport Requirements
Proper lifting and safety practices must be observed
at all times. Caution when lifting the pump as the
center of gravity is often located close to the stuffing
box/shaft seal area and not in the physical center of
the unit.
Units should be secured properly on a skid or crated
box.
3.2.2 Pump and Overhead Assembly
Do not lift pump and overhead assembly with the
motor mounted on the overhead.
3.2 Handling
The following describes how to suspension lift pump
components, assembled pumps, or pump, motor,
baseplate assemblies.
Lifting should only be done by trained personnel.
Pumps and motors often have integral lifting eyes or
eye bolts. These are intended for use in lifting the
individual piece of equipment.
Page 5
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August 2014
3.3 Storage Requirements
If the pump is inoperative for an extended of time,
flush the pump thoroughly and dry to minimize
corrosion. If there is a possibility of freezing, it is also
recommended to drain the lines and case. If the
pump is to be stored for more than 15 days, it should
be rotated once a week to lubricate and prevent
rusting of the bearings.
3.3.1 Short Term Pump Storage
•
The pump/unit should be stored in a dry room
where the atmospheric humidity is at a
constant.
•
If stored outdoors, the unit and crates must be
covered by waterproof material to avoid any
contact with humidity.
•
All openings of the assembled pump/unit
components are closed and must only be
opened when required during installation.
•
Protect all stored goods against humidity, dirt,
vermin, and unauthorized access.
protective lubrication between the balls and
raceways and lead to metal to metal cyclical
impacting. This is sometimes referred to as
false brinneling. Store the equipment as far as
possible from the source of vibrations (i.e.,
motors, rotating pumps, engines, etc.).
Isolating the equipment with rubber pads is
also an effective means of limiting vibrational
damage. Lastly, the bearings should be
rotated periodically so as to prevent extended
exposure to potential damage. The bearing
shafts should be rotated ten full rotations at a
minimum rate of once per quarter (90 days). If
high vibration levels are suspected then
rotating once per month is prudent. To protect
the bearings from moisture and contamination,
wrapping and taping the equipment in plastic
is recommended. If the environment is humid
(relative humidity over 70%) a suitable
desiccant should be used.
3.3.3 Parts Storage
Not all parts are packaged in a suitable manner from
the factory for long-term storage. To ensure a parts
satisfactory performance, the part must be protected
from corrosion and contamination.
3.3.2 Long Term Pump Storage
3.3.4 Motor and Seal Storage
Follow the guidelines when the pump or parts will be
idle for a period of one month or more. Following
these simple steps while in storage will help to
extend the life of the bearing and related equipment
reliability.
Refer to the respective manufacturer’s manuals for
storage instructions on the motor and seal.
1. All machined metal surfaces should be coated
with a suitable corrosion inhibitor to ensure the
integrity of these surfaces at the time of
installation.
2. All openings must be covered with suitable
covers to protect against contaminants.
3. Components and assemblies are required to
be stored indoors in a dry location.
Temperature range should be between 40
degrees Fahrenheit and 100 degrees
Fahrenheit.
4. When bearings are contained in equipment for
storage, a few steps should be taken to
ensure the preservation of bearing quality and
functionality. The two main concerns that
should be addressed are vibrations and
moisture. Vibration causes micro movements
between the bearing rolling elements and
raceways. This movement can displace the
4.0 Installation
4.1 Inspection upon Arrival
Your pump has been carefully inspected prior to
shipment to ensure that it meets the requirements.
Please inspect the pump upon arrival for any
damage that may have occurred during shipment,
and immediately report any damage to the carrier.
Leave all shipping covers attached to the pump unit
until it is ready for installation. If installation is to be
delayed more than 15 days, the pump shaft should
be rotated by hand once a week to lubricate the
bearings and prevent rusting.
4.2 Choosing Pump Location
1. Locate the pump as close to the liquid source
as possible so the suction pipe is short and
direct with a minimum of elbows, fittings, and
valves.
Page 6
Rev 3
August 2014
2. Place the pump in a location that allows easy
access to the unit for inspection during
operation and maintenance, which involve
removal and disassembly.
4.3 Foundation
The foundation should be sufficient to absorb any
vibration and form a permanent, rigid support for the
baseplate. A concrete foundation on a solid base is
satisfactory. Foundation bolts of the proper size
should be embedded in the concrete located as
indicated on the outline drawing.
4.4 Alignment
The pump and motor are aligned at the factory
before shipment. Realignment may be necessary
after the complete unit has been leveled on the
foundation and after the foundation bolts have been
tightened. Procedures for checking and aligning the
pump components are in section 4.0.10 and may
also be found in the Hydraulic Institute Standards.
4.5 Piping
All piping must be independently supported,
accurately aligned, and connected to the pump by a
short length of flexible piping. The pump should not
have to support the weight of the pipe or
compensate for misalignment. Install suction and
discharge bolts through mating flanges without
pulling or prying either of the flanges. All piping must
be tight. Pumps may air-bind if air is allowed to leak
into the piping. If the pump flange(s) have tapped
holes, select flange fasteners with thread
engagement at least equal to the fastener diameter
but do not bottom out in the tapped holes before the
joint is tight. The customer is responsible for proper
suction and discharge pipe design and layout to
avoid flow induced problems.
!
WARNING
Piping Forces: Take care during installation and
operation to minimize pipe forces and/or
moments on the pump casing.
4.6 Discharge Piping
An isolation valve should be installed in the
discharge line to allow for pump inspection and
maintenance.
!
WARNING
A rapidly closing discharge valve can cause a
damaging pressure surge. A dampening
arrangement should be provided in the piping.
4.7 Suction Piping
Care should be taken in sizing and locating suction
piping to prevent cavitation. A valve should be
installed in the suction line to prevent fluid from
flowing into the pump when it is shut down.
To avoid NPSH and suction problems, suction pipe
sizes must be at least greater than the pump suction
connection. Never use pipe or fittings on the suction
that are smaller in diameter than the pump suction
size.
The ideal piping configuration should have a
minimum of 10 pipe diameters between the source
and the pump suction. In most cases, horizontal
reducers should be eccentric and mounted with the
flat side on top or up with a maximum of one pipe
size reduction. Never mount eccentric reducers with
the flat side down. Horizontally mounted concentric
reducers should not be used if there is any
possibility of entrained air in the process fluid.
Vertically mounted concentric reducers are
acceptable. In applications where the fluid is
completely de-aerated and free of any vapor or
suspended solids, concentric reducers are
preferable to eccentric reducers.
Avoid the use of throttling valves and strainers in the
suction line. Start-up strainers must be removed
shortly after start-up. When the pump is installed
below the source of supply, a valve should be
installed in the suction line to isolate the pump and
permit pump inspection and maintenance. However,
never place a valve directly on the suction nozzle of
the pump. Refer to the Centrifugal Pump IOM
Section of the Hydraulic Institute Standards for
additional recommendations on suction piping.
4.8 Packing / Seal Flush Piping
An external connection should be made at the pump
so flush flow can be varied as required by valves
and the pressure can be monitored. Pipe fittings and
gauges must be corrosion resistant to the fluid being
pumped.
Page 7
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August 2014
4.9 Piping Note
PROBLEM
POSSIBLE
CAUSE
RECOMMENDED
REMEDY
Driver feet
bolt bound.
Loosen pump hold
down bolts and slide
pump and driver until
horizontal alignment is
achieved.
Baseplate
not leveled
properly,
possibly
twisted.
Determine which
corner(s) of the
baseplate are high or
low and remove or
add shims at the
appropriate corner(s)
and realign.
Baseplate
not leveled
properly,
possibly
bowed.
Determine if center of
baseplate should be
raised or lowered and
correct by evenly
adding or removing
shims.
Refer to the Hydraulic Institute Standards for
centrifugal pumps for additional piping information.
4.10 Installation and Alignment
Accurate alignment of the equipment must be
obtained and sustained. Trouble-free operation can
be accomplished by following the proper
procedures.
A properly installed base plate will be leveled with
shims, retained in place with anchor bolts, set in
concrete, and grouted with a low shrinkage grout.
When a direct drive pump and motor is mounted to a
common base plate at the factory, the coupling is
installed and aligned at that time. However,
coupling alignment must be verified before operating
the pump and motor.
Proper coupling alignment can be verified by placing
a straight edge axially across the coupling halves.
The distance between the straight edge and the
shaft should be the same within 0.1 mm (0.004
inches). Also, the angular distance between the
coupling halves should be consistent within 0.1 mm
(0.004 inches). At a minimum coupling alignment
should be checked once every 90 degrees of shaft
rotation (12:00, 3:00, 6:00 and 9:00).
When checking a v-belt motor connection, the
parallel and offset alignment of the sheave(s) to
each other must be within 1.0 mm (0.040 inches).
After connecting piping, rotate the pump drive shaft
clockwise (viewed from motor end) by hand several
complete revolutions to be sure there is no binding
and that all parts are free. Recheck shaft alignment.
If piping caused unit to be out of alignment, correct
piping to relieve strain on the pump.
After making all piping connections verify pipe
strains haven’t altered alignment. If changes have
occurred, alter piping to remove pipe strains on
pump flanges.
Operate the pump for at least an hour or until it
reaches final operating temperature. Shut the pump
down and recheck alignment while the pump is hot.
Piping thermal expansion may change the
alignment. Realign the pump as necessary.
Unable to
obtain
horizontal
(side to
side)
alignment,
angular, or
parallel.
Unable
obtain
vertical
alignment,
angular, or
parallel.
5.0 Coupling and V-Belt Guard
!
WARNING
Power must never be applied to the driver when
the coupling guard is not installed.
Coupling guards are safety devices intended to
protect workers from inherent dangers of the rotating
pump shaft, motor shaft, and coupling. It is intended
to prevent entry of hands, fingers, or other body
parts into a point of hazard by reaching through,
over, under, or around the guard.
No standard coupling guard provides complete
protection from a disintegrating coupling. The
coupling conforms to the U.S.A. standard ASME
B15.1, “Safety Standard for Mechanical Power
Transmission Apparatus.”
See the following table for possible alignment
issues.
Page 8
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August 2014
6.0 Commissioning, Start-Up and
Shutdown Instructions
6.1 Commissioning
Use proper eye and face protection when
examining, adjusting, maintaining, or in any other
way working on the pump. Read all instruction tags
on the pump.
!
WARNING
The electrical connections must be disconnected
and locked out. Make sure the pump cannot be
switched on accidentally.
Liquids posing health hazards must be
decontaminated and disposed of ensuring that there
are no risks to persons or to the environment.
Prior to start-up, perform the following tasks:
1. Ensure the pump, suction line, and the tank
are vented.
7.1 Periodic Maintenance
2. Make sure the unit is properly connected to
the electric power supply.
The following table contains recommended service
checks that should be performed on a periodic
basis.
3. Confirm that the direction of shaft rotation is
correct. The correct direction of shaft rotation
is clockwise when viewed from the motor end
of the pump.
4. Ensure that all auxiliary connections are
connected and functioning.
5. If the pump is oil lubricated ensure the oil level
is correct. The correct amount of oil is present
when the level is in the middle of the sight
glass.
6.2 Start-Up
Ensure all valves are open and all auxiliaries are on.
After start-up check pump for leaks and check
operating conditions. Stand at a safe distance during
start-up.
6.3 Shutdown
Initial
Start-Up
Weekly
Flow, Pressure,
Temp. (7.1.1)
X
X
Visual (7.1.2)
X
X
Noise Vibration
X
X
Lubricate
X
X
Monthly
X
7.1.1 Flow, Pressure, and Temperature
Monitoring
All flow, pressure, and temperature gauges should
be monitored to ensure that the pump is operating
within specified limits. If the frame temperatures are
monitored, this temperature generally should not
exceed 71°C (160°F).
Turn off drive. Allow pump to come to a complete
stop before disconnecting auxiliaries and closing
valves.
7.0 General Service and
Maintenance
General service and maintenance should be carried
out by authorized and trained operators who are
familiar with these operating instructions.
Page 9
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August 2014
7.1.2 Visual Inspections
7.2.4 Oil Lubrication
Periodic visual inspection should be made of the
pump and its installation.
Viscosity grade recommendations based on
temperature are listed in the following table.
This inspection should include the following:
ISO Grade
Temperature
1. All mounting supports should be secure.
2. All external nuts, bolts, and fittings should be
tight.
3. All suction and discharge piping should be
secure.
4. All surfaces and joints should show no signs of
leakage.
7.1.3 Pump Wash Down
Periodic maintenance can involve the use of high
pressure sprays to remove excess dirt and debris.
When using such equipment, in order to prevent
liquid contamination which could damage the
bearings, it is essential to ensure the bearing
isolators are not sprayed, directly or indirectly.
VG68
63°C to 76°C
145°F to 170°F
VG150
77°C to 92°C
171°F to 199°F
VG220
9°C to 121°C
200°F to 250°F
In the absence of existing preventative maintenance
procedures, the oil level should be checked at the
time of pump installation, start-up and then once
weekly thereafter, and the oil should be changed
once every three months.
7.2.5 Oil Capacities
Approximate oil capacities are listed in the following
table, the bearing unit should be filled until the sight
glass is half full with oil:
7.2 Lubrication
7.2.1 Grease Lubrication
Size
Oil Level
Liters (Quarts)
50 (2x2)
0.6 (0.6)
The grease base oil can be mineral or synthetic with
synthetic base oil being preferred for bearing
temperatures above 93°C (200°F). The consistency
should be a NLGI grade 2, with a lithium or lithium
complex thickener (soap).
75 (3x3)
0.7 (0.8)
100 (4x3)
1.0 (1.1)
7.2.2 Initial Bearing Grease Fill
150 (6x4)
1.3 (1.4)
Bearings in pumps shipped from the factory come
with the bearings pre-packed with grease. When
replacing bearings, pack the bearings 100% full of
grease, and fill the pump housing cavity around the
bearing 30% to 50% full of grease.
200 (8x6)
2.1 (2.2)
250 (10x8)
4.6 (4.8)
300 (12x10)
5.9 (6.2)
350 (14x12)
5.6 (6.0)
7.2.3 Grease Lubrication Interval
Re-lubrication intervals are difficult to determine.
Once intervals are established through plant
practices or experiences, regular lubrication intervals
should be maintained. In the absence of preexisting practices, refer to Appendix 1 for guidelines.
Page 10
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7.3 Wear Adjustment
!
CAUTION
Never adjust the clearance while the pump is
running.
The impeller running clearance in pumps sizes 150
(6x4) and smaller is controlled by an adjustment bolt
located under the bearing cartridge.
On pumps sizes 200 (8x6) and larger two
adjustment features are provided. In addition to the
adjustment bolt located under the bearing cartridge,
the suction cover is adjustable. This allows control
of the impeller and expeller running clearance.
On all pumps, the suction cover can be rotated to
compensate for uneven wear.
7.4 General Servicing Attributes
Case joint disassembly under difficult circumstances
is provided for. Fasteners are located in slotted or
through hole connections and can be sacrificially
removed without damaging the connected
components, if need be. When troublesome
conditions arise with case joint separation, the joint
designs allow for use of prying tools.
Seal stuffing boxes, fastened directly to the bracket,
can be removed directly or if troublesome can be
removed while still attached to the bracket for better
accessibility to any frozen fasteners.
The bearing cartridge fork allows the bearing
cartridge to be easily disassembled from the
pedestal. Flats on the bearing cartridge provide
accessibility to the bearing caps for application of
force to aid in removal of the bearing caps.
Flanges are separate parts supplied with either
ANSI 150 lb or ISO PN 16 connections. Tabs
located on the case and suction cover directly
behind the cone where the flange seats provide a
bearing surface that aid with separation of the flange
from the split ring. The flange clears the tabs while
the split ring does not. With the flange assembly
resting on the tabs, application of a sharp blow to
the flange should separate the two pieces. With the
aid of a screw driver, prying open the split ring
makes it possible to slip it over the cone. Following
that, the flange itself can be lifted free of the part.
7.5 Impeller Replacement
Note: Any work on non-pump equipment shall be
governed by the specifications and regulations of the
manufacturer. Ensure that lockout tags are in place.
Do not apply heat to impeller hub or nose.
Removal of the impeller first requires removal of the
suction cover. Access to the discharge nozzle on
the case is also required, as it will be necessary to
insert a bar into the discharge neck to contact the
impeller and prevent it from rotating as it is
unthreaded from the shaft.
!
CAUTION
On all but the smallest pumps, a lifting fixture to
support the weight of the impeller at the impeller
eye during this operation is necessary.
The impeller is tightened by running torque during
normal operation. A torsional jolt is usually required
to loosen the impeller. On pumps size 150 (6x4) and
smaller, a shock force applied to a keyed shaft
wrench located on the drive end of the shaft should
provide the force necessary to break free the
impeller. On pumps size 200 (8x6) and larger a
sacrificial brass release collar (shown below) is
provided to relieve the impeller thread load. Prying
loose the pieces will relieve the impeller load and
allow removal. A groove in the release collar sleeve
provides a location for a screwdriver blade, lightly
tapping the screw driver with a hammer to move the
release collar along the shaft will aid with
disassembly of the release collar.
Note: Care should be taken to prevent marring of
the shaft or shaft keyway when using a shaft
wrench.
Release Collar
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7.6 Designation
Example:
EMW 150M 6x4
Pump:
EMW
Suction Nozzle (in mm):
50 through 350
(See the table below)
Hydraulic Type:
Metal (M)
Rubber (R)
Imperial Size (suction x discharge):
Pump
Type
50
75
100
150
200
250
300
350
M/R
M/R
M/R
M/R
M/R
M/R
M
M
Suction
mm (in)
50 (2)
75 (3)
100 (4)
150 (6)
200 (8)
250 (10)
300 (12)
350 (14)
open to allow inspection of or removal of the impeller
from an installed pump. The casing can be rotated
in 45 degree increments (90 degrees for the size 75
and 50 pumps) to accommodate a variety of
discharge requirements.
8.1.2 Impeller
The impeller with its extra thick shrouds and vanes
and wide open flow passages for handling large
objects, maintains excellent performance
characteristics throughout its wear life. A closed
type impeller is used with all sizes except the size 50
(2x2) pump, which uses a semi-open type impeller.
Discharge
mm (in)
50 (2)
75 (3)
75 (3)
100 (4)
150 (6)
200 (8)
250 (10)
300 (12)
7.7 Drainage / Disposal
Prior to drainage of the product from pump, review
the Material Safety Data Sheet (MSDS) of the
product. Wear appropriate protective clothing.
Follow relevant laws, local codes and safety
procedures when disposing of product.
8.0 General Instructions for
Ordering Parts
8.1.3 Bearing Cartridge
The shaft is constructed from high strength alloy
steel, mounting paired taper roller thrust bearings
and a spherical roller radial bearing protected by
labyrinth isolators. The bearing cartridge assembly is
designed for long life in the harshest conditions and
is available with either grease or oil lubrication.
8.1.4 Sealing System
The seal chamber is designed for easy
maintenance, equipped with large openings for all
around accessibility.
Three seal systems are available.
•
Expeller with Packing Seal
•
Packing Seal
•
Mechanical Seal
•
Provide part numbers
•
Diaphragm Seal with expeller
•
Provide size and model of pump
•
Dynamic Seal with expeller
•
Provide serial number if available or if a
specialty pump
8.1 Design Details
Designed as a class III heavy duty end suction slurry
pump, the pumping chamber, impeller and expeller
are constructed with high chrome, hard iron
materials.
8.1.1 Pump Casing
The extra heavy wall thickness and special volute
design extends wear life. The front of the case is
8.1.4.1 Expeller with Packing Seal
The expeller provides a positive hydraulic sealing
arrangement when the pump is running. The
packing provides a static seal when the pump is not
running. The expeller will keep slurry from coming in
contact with the packing when the pump is running,
so abrasive wear on shaft sleeve is greatly reduced.
However, the packing must be lubricated to
compensate for the pumping action of the expeller,
which will tend to dry out the seal chamber. Grease
is the recommended lubricant for applications where
the use of a liquid lubricant is undesirable. Graphite
packing is standard.
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Expeller seal performance is dependent upon
suction pressure and pump rotational speed.
Operating the pump at other than the specified
conditions for which it was built can result in
unsatisfactory seal performance, excessive wear,
and/or premature failure of the seal and/or pump.
8.1.4.2 Packing Seal
The Packing seal provides a simple alternative
solution to either an expeller seal or mechanical
seal. Graphite packing is standard. A packing flush
is always recommended; however, in some
applications, dry running packing (packing that is
lubricated solely by the liquid being pumped) will
also work.
8.1.4.3 Mechanical Seal
The EMW pump seal chamber is designed to
accommodate a mechanical seal. Seal envelope
requirements vary from supplier to supplier and
single, double, cartridge, and non-cartridge designs
can work. But, before specifying a seal consult with
a Wilfley Representative as engineering approval is
required for such applications.
8.1.4.4 Diaphragm Seal with Expeller
The diaphragm seal is a simple flush-less dynamic
seal. The expeller creates suction in the seal
chamber that pulls open the diaphragm while
rotating. This creates a sealing air pocket while
running. Upon stopping, the diaphragm will push
back against a rotating seal face using the force of
the liquid in the case to create a static seal.
Expeller seal and dynamic seal performance is
highly dependent upon suction pressure and pump
rotational speed as well as properly adjusted internal
clearances. Operating the pump at other than the
specified conditions for which it was built can result
in unsatisfactory seal performance, excessive wear,
8.1.4.4 Dynamic Seal with Expeller
The dynamic seal is a flush-less proprietary sealing
solution that uses an expeller to create an air pocket
to seal the pump while rotating, and a specially
designed static seal that can be adjusted to open
and close specifically at the application speeds and
pressures.
clearances. Operating the pump at other than the
specified conditions for which it was built can result
in unsatisfactory seal performance, excessive wear,
9.0 General Assembly Information
The EMW pump is metric by design. Metric
fasteners are used throughout with the following
exceptions. All pipe fittings use imperial National
Pipe Threads (NPT). On EMW metal pumps
produced in the U.S.A. the square head bolts and
nuts used to assemble the case are imperial. The
flat washers used with these fasteners, however, are
metric. Imperial washers are too large to register
correctly in the case and bracket counter bore
reliefs, and should not be substituted here.
Whenever a pump is rebuilt, all o-rings and gaskets
should be replaced. On pumps size 200 and larger,
the release collar is a sacrificial component which
must be replaced every time a pump is rebuilt.
In general, parts should be cleaned to remove such
things as debris, dirt, or rust inhibitor coatings and
also inspected for damage. If reconditioned or
existing parts are going to be used, inspect them for
wear before installing. Before using any parts, all
sealing surfaces should be inspected for cleanliness
and damage. Replace any damaged fasteners. All
fastener threads and the impeller thread should be
coated with an anti-seize lubricating compound prior
to using.
On the metal pumps the discharge and suction
flanges are loose parts so that either an ISO class
PN16 or ANSI class 150 lb flange connection can be
made. On rubber lined pumps, as a standard, the
case shell suction and discharge flange connections
are PN16 metric thread tapped holes. ANSI class
150 lb flange connections are available on rubber
lined pumps by special request.
When bolted joints are encountered care should be
taken to incrementally tighten all fasteners in a
crossing pattern until metal to metal contact is
achieved between the mating parts before torqueing
the fasteners to the final value. Exception: A gap,
approximately 1 mm (0.040 inches) wide, will exist
between the thrust bearing cap and the bearing
cartridge when properly assembled. This bearing
cap should not be over tightened.
Expeller seal and dynamic seal performance is
highly dependent upon suction pressure and pump
rotational speed as well as properly adjusted internal
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9.1.3 Shaft Handling Tool
!
CAUTION
The tapped hole in the top of the bearing
cartridge is for a lifting eye used to handle the
bearing cartridge assembly. It is not to be used
for lifting a pump.
9.1 Specialized Tools for Assembly
and Disassembly
9.1.1 Impeller Tool
On all but the smallest size pumps, an impeller lifting
fixture that registers in the eye of the impeller is
required for inserting an impeller into or removing an
impeller from a case. If a crane will be used, a “C”
shaped bent frame lifting fixture with a lifting point
located above the impeller center of gravity when
the impeller is in a horizontal position is
recommended.
A 12 mm tapped hole in the end of the shaft
provides a location for a hoisting attachment such as
an eyebolt to assist with vertical positioning of the
shaft for insertion into or removal from a bearing
cartridge.
9.1.4 Radial Bearing Alignment Tool
A tool to align the radial bearing outer race during
vertical insertion or removal of a shaft assembly into
or from a bearing cartridge is required. A tool that
shoulders against the radial bearing outer race, slip
fits over the drive end of the shaft and is secured in
the keyway by a set screw is recommended. To
avoid damaging the shaft, the set screw should only
be tightened against the shaft keyway flat.
9.1.2 Shaft Wrench
A shaft wrench keyed to fit the drive end of the shaft
is recommended for aiding with the tightening or
releasing of an impeller.
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10.0 General Pump Assembly Sequence
10.1 Power End Assembly
Step 1 – Shaft assembly. The thrust bearings (16) are two taper roller bearings mounted to the shaft in a faceto-face arrangement. The radial bearing (18) is a spherical roller bearing. The thrust bearings are a matched pair
and cannot be assembled by mixing and matching pairs. Preheating the bearings for assembly will allow the
bearings to slip onto the shaft with a butt fit of the inner race of the bearings against the appropriate shaft
shoulder. Please note that the thrust bearing outer race for the inner most bearing will have to be placed on the
shaft before installing the thrust bearings. The thrust bearings (16) are located on the threaded side of the shaft,
and the radial bearing (18) is located on the keyed side of the shaft. Be sure that the bearings are cooled before
moving on to the next step.
Step 1 – Shaft Assembly
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Step 2 – Bearing Cartridge Assembly. To install the shaft assembly from Step 1 into the bearing cartridge (99),
the shaft should be vertically lowered, radial bearing or keyed side first, into the bearing cartridge. If unsure which
side of the bearing cartridge is which, the side that has a lip in the bore is the thrust bearing side, and that side will
be the side the shaft is lowered into. There is a threaded hole in the shaft (6) to allow a lifting eye for
maneuvering the shaft assembly. In addition, a sleeve designed to fit around the keyed portion of the shaft and
mate up against the radial bearing is needed to allow for insertion through the tight bore clearances (see figure
below). If the bearings are grease lubricated the bearings and the space directly inboard from the bearings
should be packed with grease before inserting the shaft assembly into the bearing cartridge. You must be careful
when lowering the thrust bearing into the cartridge making sure the outer races are inserted squarely. At this
point the bearing cartridge can be rested horizontally in the pedestal assembly (Step 3), or on a workbench cradle
and
all
assembly
tools
may
be
removed.
Step 2 – Bearing Cartridge Assembly (Grease Lube)
NOTE: Pumps size 75 (3x3) and smaller only require quantity 1 of items 99B, 143, and 144.
Step 2 – Bearing Cartridge Assembly (Oil Lube)
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Step 2 – Lowering the shaft into the bearing cartridge
Press fit the bearing isolaters (47) and (49) into the bearing caps (35) and (37) respectively. Next install the orings (35B) into the thrust bearing cap (35), and (37A) into the radial bearing cap (37). If the bearings are grease
lubricated, the area directly outboard from the bearings should be packed with grease prior to assembling the
bearing caps. The bearing caps are assembled onto their respective sides using hardware (35A) and (37A).
Please note that when installing the thrust bearing cap (35), a gap of approximately 1mm (0.040 inches) will be
visible between the bearing cartridge and bearing cap. Do not over tighten this bearing cap. The bearing cap
screws (35A) and (37A) should be tightened slowly in a star pattern and should not be over tightened as the
bearing cap can deform and cause the bearing to be misaligned and seize up. When installing the bearing caps,
it may be difficult to push the o-ring over the shaft shoulder, so it is recommended to use the cap screws to pull
the bearing cap evenly into place. If the pump is grease lubricated, thread two grease fittings (99E) into the top of
the bearing cartridge and give each bearing a shot of grease. If the pump is oil lubricated, assemble the oil drain
plug (99B), oil sight glass (143), and temperature gauge (144) into the holes on the side of the cartridge, and
install the oil fill plug (99A) on the top of the bearing cartridge.
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Step 3 – Pedestal Assembly. Install the clearance adjustment bolt (149), nuts (149B), and washers (149C) into
the pedestal (53). At this point it is recommended to bolt the pedestal to a rigid base or structure to prevent it
from tipping forward when the wet end of the pump is assembled. On pumps size 100 (4x3) and smaller,
assemble the gland half of the case (1C) with socket head cap screws (71F). On pumps size 150 (6x4) and
larger, assemble the gland half of the case (1C) with hex-head screws (71F) and flat washers (71G).
Step 3 – Pedestal Assembly
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Step 4 – Power End Assembly. To complete the assembly of the power end, lower the bearing cartridge
assembly from Step 2 onto the pedestal assembly from Step 3, making sure the threaded side of the shaft is on
the bracket side. Loosely install the bearing cartridge clamps (54) using hardware (54A), (54B), and (54C).
Remove the lifting eye from the bearing cartridge and replace it with a hex cap screw and washer as this lifting
eye location is not rated to lift the full pump weight.
Step 4 – Power End Assembly
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Step 5 – Shaft sleeve assembly (Pump size 150 (6x4) and smaller). Install the o-ring (119B) into the ID
groove in the shaft sleeve (14). Slide the shaft sleeve, chamfered end first, onto the front end of the shaft (6).
The sleeve will stop on contact with the bearing isolator. Be sure to push the shaft sleeve completely on, until it
seats against the thrust bearing (16). At no time should a bladed tool (like a screwdriver) be used to drive the
sleeve on.
Shaft Sleeve Installation (Pumps Size 150 (6x4) and Smaller)
Incorrectly installed shaft sleeve
(Shoulders against thrust bearing isolator o-ring
Correctly installed shaft sleeve
(Shoulders against thrust bearing)
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Step 5 - Release Collar Sleeve Assembly (Pump size 200 (8x6) and larger) – Install the o-ring (36A) in the ID
groove in the release collar sleeve (36B). Slide the release collar sleeve, chamfered end first, onto the shaft (6).
Slide the release collar cover (36C) onto the release collar shaft sleeve past the groove on the release collar shaft
sleeve and loosely install the square head set screw (36D) into the cover (36C). If the release collar (36) is not
already in two pieces, cut the release collar into two halves at the two scored locations and notch to 45 degrees
as shown above if necessary. Orient the two halves so that the grooved faces are facing out and position on the
shaft. Slide the release collar cover (36C) over the two halves of the release collar (36) and tighten the square
head screw (36D) so that it bottoms out in the groove on the release collar sleeve (36B).
The release collar is split to allow removal and reinstallation on a fully assembled pump. Removing the release
collar will relieve the pressure on the impeller threads so the impeller can be removed easily after use.
To remove a release collar from a fully assembled pump loosen the square head set screw (36D), slide the
release collar cover (36C) towards the bearing cartridge to expose the release collar (36) and use the notches in
the release collar as pry points to work the collar out.
Release Collar Sleeve Assembly (Pumps Size 200 (8x6) and Larger)
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Shaft Sleeve / Release Collar Installation (Pumps Size 200 (8x6) and Larger)
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10.2 Wet End Assembly
Step 6 – 7: Seal and Wet End Assembly. There are a variety of seals available for the EMW pump. Please turn
to the appropriate page in table 6-1 based on which seal is installed in your pump.
Table 6-1: Seal Assemblies by Page
Seal
Section
Page
Expeller with Packing
10.2.1
23-26
Packing
10.2.2
27-30
Mechanical Seal
10.2.3
31-34
SolidLock™ Lite (Diaphragm Seal)
Contact Wilfley Representative
SolidLock™ Dynamic Seal
Contact Wilfley Representative
10.2.1 Expeller with Packing
Step 6-1 – Packing Seal Assembly - Expeller Seal. The expeller seal consists of an expeller (4), which creates
a dynamic seal, and a packing seal, which creates a static seal. On pumps, size 100 (4x3) and larger, to prevent
the expeller from slipping when pumping high density slurries, a flat section inside the expeller bore engages a flat
on the shaft.
Step 6-1 Expeller with Packing Seal Components (Weep Configuration Shown)
The packing seal consists of a stuffing box (83X) three rings of packing (13), a lantern ring (29), a spacer ring
(63), a gland plate (17), a gland ring (17C), two gland studs (17A) and two gland nuts (17B). When studs (17A)
are being installed, coat the stud threads with a thread locking compound when assembling. Joints of successive
rings should be staggered and kept at least 90° apart.
The seal housing (83X) is provided with two port configurations, weep and flush. An “A” stamp next to the port
identifies the weep port while a “B” stamp next to the port identifies the flush port.
To prevent a packing seal failure the packing in all expeller sealed pumps must be lubricated during pump
operation. An o-ring (71C) seals the case and expeller cover joint and another o-ring (83C) seals the expeller
cover and the stuffing box joint as seen in the figures below.
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Install the spacer ring (63) into the stuffing box (83X). Then depending on the flush or weep style configuration,
install the packing rings (13) and lantern ring (29). Place the gland ring (17C) on the packing, install the studs
(17A), and tighten down the gland plate (17) using two nuts (17B). The nuts only need to be loosely installed for
initial installation. They should be tightened after the pump is fully assembled.
Expeller with Packing (Weep Configuration)
The weep configuration (spacer ring, packing ring, lantern ring, and two rings of packing) directs a lesser amount
of coolant towards the seal chamber than a flush configuration and uses less flush water.
Expeller with Packing (Flush Configuration)
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The flush configuration (spacer ring, lantern ring, and three rings of packing) directs the majority of the coolant
towards the seal chamber, pushing solids away from the packing using more flush water.
Step 6-2 Expeller with Packing
Step 6-2 – Wet end assembly – Expeller/Packing Seal. Install the shaft o-ring (119B) into the shaft sleeve (14)
and insert the shaft sleeve onto the shaft (6) butting it up against the release collar (36) or thrust bearing
depending on your size pump. Take the stuffing box assembly (83X) and slide it onto the shaft sleeve (14). Bolt
the stuffing box to the gland case half (1C) using the flat head cap screws (83A) and hex nuts (83G). Next place
the stuffing box o-ring (83C) into the stuffing box groove and insert the expeller cover (21B) into the bracket.
Make sure that the expeller cover (21B) ID is over the lip on the stuffing box (83X). Insert the shaft sleeve o-ring
(119A) onto the end of the shaft sleeve (14) and but the expeller (4) up against it with the expeller vanes pointed
towards the back of the pump. Note that the packing rings, lantern ring, and spacer ring (13), (29), and (63) can
be installed and removed after the pump has been assembled, but the gland ring (17C) must be around the shaft
before assembly of the wet end.
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Step 7 Gland Half Casing and Impeller Assembly – Expeller/Packing Seal – Assemble the gland half case
liner (21C) with hardware (21H, 21J, 21K) to the case gland half. Install the expeller o-ring (4A) in the expeller (4)
and thread the impeller (2) onto the shaft. Tighten the impeller.
Step 7 - Case Assembly (Expeller Seal)
The case gland half liner used with an expeller seal contains stationary vanes and a small annular opening
around the shaft.
The impeller used with an expeller seal has long pump out vanes on the backside that extend almost all the way
down to the hub.
Case Gland Half Liner
Impeller
Please proceed to Section 10.4, Step 8 on page 35 for the next assembly step.
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10.2.2 Packing
Step 6-1 – Packing Seal Assembly. The packing seal creates a simple static and dynamic seal.
Step 6-1 - Packing Seal Components (Weep Configuration Shown)
The packing seal consists of a stuffing box (83X) four rings of packing (13), a lantern ring (29), a spacer ring (63),
a gland plate (17), a gland ring (17C), two gland studs (17A) and two gland nuts (17B). When studs (17A) are
being installed, coat the stud threads with a thread locking compound when assembling. Joints of successive
rings should be staggered and kept at least 90° apart.
Install the spacer ring (63) into the stuffing box (83X). Then depending on the flush or weep style configuration,
install the packing rings (13) and lantern ring (29). Place the gland ring (17C) on the packing, install the studs
(17A), and tighten down the gland plate (17) using two nuts (17B). The nuts only need to be loosely installed for
initial installation. They should be tightened after the pump is fully assembled.
The seal housing (83X) is provided with two port configurations, weep and flush. An “A” stamp next to the port
identifies the weep port while a “B” stamp next to the port identifies the flush port.
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Packing Seal (Weep Configuration)
The weep configuration (spacer ring, packing ring, lantern ring, and three rings of packing) directs a lesser
amount of coolant towards the seal chamber than a flush configuration and uses less flush water.
Packing Seal (Flush Configuration)
The flush configuration (spacer ring, lantern ring, and four rings of packing) directs the majority of the coolant
towards the seal chamber, pushing solids away from the packing using more flush water.
Page 28
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Step 6-2 - Packing Seal
Step 6-2 – Wet end assembly –Packing Seal. Install the shaft o-ring (119B) into the shaft sleeve (14) and insert
the shaft sleeve onto the shaft (6) butting it up against the release collar (36) or thrust bearing depending on your
size pump. Take the stuffing box assembly (83X) and slide it onto the shaft sleeve (14). Bolt the stuffing box to
the gland case half (1C) using the flat head cap screws (83A) and hex nuts (83G). Next place the stuffing box oring (83C) into the stuffing box groove. Insert the shaft sleeve o-ring (119A) onto the end of the shaft sleeve (14)
and butt the spacer sleeve (34) up against it. Note that the packing rings, lantern ring, and spacer ring (13), (29),
and (63) can be installed and removed after the pump has been assembled, but the gland ring (17C) must be
around the shaft before assembly of the wet end.
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Step 7 Gland Half Casing and Impeller Assembly –Packing Seal – Assemble the gland half case liner (21C)
with hardware (21H, 21J, 21K) to the case gland half. Install the spacer o-ring (4A) in the spacer sleeve (34) and
thread the impeller (2) onto the shaft. Tighten the impeller.
Step 7 – Gland half assembly with impeller
A case gland half liner used with packing will always have a large bore taper box with static anti-swirl vanes and a
large annular opening around the shaft.
Either impeller shown below can be used with a packing seal pump (the one with the long backside pump out
vanes is standard).
Impeller
A case gland half liner used with packing will always have a large bore taper box with static anti-swirl vanes and a
large annular opening around the shaft.
Either impeller shown below can be used with a packing seal pump (the one with the long backside pump out
vanes is standard).
Please proceed to Section 10.4, Step 8 on page 35 for the next assembly step.
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10.2.3 Mechanical Seal
Step 6 - Mechanical Seals. The seal chamber space available for mounting a mechanical seal (89S) is
sufficiently large to accommodate most OEM mechanical seal products.
The case gland half liner (21C) in a mechanical seal pump is the same one used with a packing seal pump.
Cartridge Style Mechanical Seal
Semi-Cartridge Style Mechanical Seal
When a cartridge seal is employed, the same spacer sleeve (34) used with a packing seal is also used. Semicartridge style seals can also be installed. The semi-cartridge mechanical seal shown incorporates the seal gland
into the stuffing box and the rotary seal face replaces the spacer sleeve. This type of seal generally requires less
radial space than a cartridge style seal.
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Mechanical Seal
Step 6 – Seal Assembly - Mechanical Seals – Install the seal assembly (89) into the stuffing box (83). The
shaft sleeve (14) and o-ring (119B) can be installed on the shaft before installing the seal assembly or it can be
inserted into the seal assembly and slid onto the shaft when the stuffing box is assembled to the bracket. Install
the o-ring (83C) in the stuffing box
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August 2014
Step 7 Gland Half Casing and Impeller Assembly –Packing Seal – Assemble the gland half case liner (21C)
with hardware (21H, 21J, 21K) to the case gland half. Install the spacer o-ring (4A) in the spacer sleeve (34) and
thread the impeller (2) onto the shaft. Tighten the impeller.
Step 7
A case gland half liner used with a mechanical seal will always have a large bore taper box with static anti-swirl
vanes and a large annular opening around the shaft.
Only an impeller with short backside pump out vanes can be used with a mechanical seal pump.
Impeller
!
CAUTION
Do not use an impeller with long backside pump out vanes in a mechanical seal pump because it can reduce the
stuffing box pressure to a level low enough to damage the mechanical seal.
Page 33
Rev 3
August 2014
Step 7 - Semi-Cartridge Style Mechanical Seal. Assemble the case gland half liner (21C) with hardware (21H,
21J, 21K) to the case gland half. If a semi-cartridge seal of the type shown in Assembly Step 6 is used install the
o-ring (119A) into the shaft sleeve (14) and slide the rotary seal face onto the shaft. Install the o-ring supplied
with the mechanical seal into the mechanical seal rotary face and thread the impeller (2) onto the shaft. Tighten
the impeller. Do not set the mechanical seal.
Step 7
A case gland half liner used with a mechanical seal will always have a large bore taper box with static anti-swirl
vanes and a large annular opening around the shaft.
Only an impeller with short backside pump out vanes can be used with a mechanical seal pump.
Impeller
!
CAUTION
Do not use an impeller with long backside pump out vanes in a mechanical seal pump because it can reduce the
stuffing box pressure to a level low enough to damage the mechanical seal.
Page 34
Rev 3
August 2014
10.4 Case (Suction Half) Assembly
10.4.1 Pumps Size 150 (6x4) and Smaller
Step 8 – Suction Assembly (Pumps Size 150 (6x4) and Smaller) – Assemble the case suction half liner (21D)
with hardware (21E, 21F, 21G) to the case suction half (1D). Assemble the lifting eye (1K) with hardware (1M) to
the case suction half.
Step 8 – Suction Assembly
10.4.2 Pumps Size 200 (8x6) and Larger
Step 8 – Suction Assembly (Pumps Size 200 (8x6) and Larger) – Assemble the case suction half liner (21D) to
the case suction half (1D). Install the suction cover liner (9E) into the suction cover (21A). Assemble the four
lifting eyes (9C) with hardware (71F) to the case suction cover. Assemble the suction cover to the case suction
half with hardware (21E, 21F, 21G).
Step 8 - Case Suction Half (Size 200 (8x6) Pumps and Larger)
Page 35
Rev 3
August 2014
Step 9 – Case Assembly. Insert the two alignment pins (1H) into the case gland half, taper end first, from the
backside. Insert two cotter pins (1J) into each pin to hold them in place. Assemble the case suction half to the
case gland half with the aid of the two alignment pins. Secure in place with hardware (1E, 1F, 1G).
Step 9 – Case Assembly
Step 10 – Seal Adjustment
Packing with Expeller – Make sure the packing gland nuts (17B) – shown in Step 6 - are only finger tight.
(These nuts will be tightened as needed when the pump is installed and running).
Packing – Make sure the packing gland nuts (17B) shown in step 6 - are only finger tight. (These nuts will
be tightened as needed when the pump is installed and running).
Mechanical Seal - Set the mechanical seal per the manufacturer’s instructions.
Page 36
Rev 3
August 2014
10.5 Seal Guard Assembly
Step 11 (Guard Assembly) – Assemble the upper and lower seal chamber guards (132) and (133) and hardware
(132A) and (132B) to the pedestal (53).
Step 12 – Seal Guard Assembly
Page 37
Rev 3
August 2014
10.6 Setting Clearances
Step 10
Step 12 –The impeller running clearance is controlled by adjusting the bearing cartridge position in the pedestal.
While this adjustment is primarily intended for controlling the impeller running clearance in an expeller sealed
pump that is experiencing low expeller performance, this adjustment can be employed to move the bearing
cartridge backwards, thus reducing the expeller running clearance. However, controlling the expeller running
clearance in such a manner will shorten the life of the pump due to an increase in the wear rate resulting from the
increase in impeller running clearance and may result in loss of performance.
To set the impeller running clearance, first ensure the bearing cartridge clamp bolts are loose, then loosen the
hex nuts (149B) on the bearing cartridge adjustment screw (149) located underneath the bearing cartridge (99) in
the pedestal (53). Move the bearing cartridge forward with the aid of the outboard hex nut on the bearing
cartridge adjustment screw until the impeller (2) contacts the suction cover (9). While making this adjustment
slowly rotate the shaft (6) in a clockwise direction, as viewed from the back of the pump. When contact occurs,
back off the outboard hex nut on the adjustment screw, run up the inboard hex nut against the fork on the bearing
cartridge, and tighten one hex flat (60 degrees) to set the impeller running clearance. Run the outboard hex nut
up against the fork and tighten both nuts to secure the bearing cartridge in place. Tighten both hex nuts and then
verify the shaft turns freely. Tighten the bearing cartridge clamp bolts. The impeller running clearance should be
approximately 0.5 mm (0.02 inches). A dial indicator is recommended for a more precise setting.
Impeller Clearance Adjustment (Rubber Lined Pump Only)
Pump Size
50 (2x2)
75 (3x3)
100 (4x3)
150 (6x4)
200 (8x6)
250 (10x8)
Number of
Flats (Degrees)
4 (240°)
3 (180°)
3 (180°)
4 (240°)
8 (540°)
8 (540°)
Approximate Impeller
Clearance
2 mm
1.5 mm
1.5 mm
2 mm
4 mm
4 mm
Page 38
Rev 3
August 2014
11.0 General Specifications
11.1 Forces and Moments
Forces and moments only apply to static pipelines. The values are applicable when pump is installed on
a grouted and even foundation.
NOTE: Discharge nozzle coordinate system always moves with nozzle angle (Fz is always in direction of flow).
BRANCH
SIZE
50
75
100
150
200
250
300
350
BRANCH
SIZE
2
3
4
6
8
10
12
14
Discharge
MXd
FXd (N) FYd (N) FZd (N)
(N-m)
7110
5690
14450 3570
7840
6270
15180 3930
8590
6890
15930 4290
10110
8090
17450 4990
11700
9340
19040 5690
13390 10710 20730 6380
15230 12180 22560 7070
17300 13830 24640 7740
Discharge
MXd
FXd (lb) FYd (lb) FZd (lb)
(ft-lb)
1600
1280
3250
2640
1760
1410
3410
2900
1930
1550
3580
3160
2270
1820
3920
3680
2630
2100
4280
4200
3010
2410
4660
4700
3420
2740
5070
5210
3890
3110
5540
5710
Suction
MYd
MZd
MXs
MYs
MZs
FXs (N) FYs (N) FZs (N)
(N-m) (N-m)
(N-m) (N-m) (N-m)
3570 5420 14450
7110
5690
5420 3570 3570
3930 5960 15180
7840
6270
5960 3930 3930
4290 6500 15930
8590
6890
6500 4290 4290
4990 7570 17450 10110 8090
7570 4990 4990
5690 8620 19040 11700 9340
8620 5690 5690
6380 9670 20730 13390 10710 9670 6380 6380
7070 10710 22560 15230 12180 10710 7070 7070
7740 11730 24640 17300 13830 11730 7740 7740
MYd
(ft-lb)
2640
2900
3160
3680
4200
4700
5210
5710
Suction
MZd
MXs
F (lb) FYs (lb) FZs (lb)
(ft-lb) Xs
(ft-lb)
4000
3250
1600
1280
4000
4390
3410
1760
1410
4390
4790
3580
1930
1550
4790
5580
3920
2270
1820
5580
6360
4280
2630
2100
6360
7130
4660
3010
2410
7130
7900
5070
3420
2740
7900
8650
5540
3890
3110
8650
MYs
(ft-lb)
2640
2900
3160
3680
4200
4700
5210
5710
MZs
(ft-lb)
2640
2900
3160
3680
4200
4700
5210
5710
Page 39
Rev 3
August 2014
11.2 Noise Characteristics
When running the pump within the normal limits of operation and on clear liquids, the sound pressure level for the
pump alone does not exceed 80 dBa.
Coarse solids, froth, or cavitation conditions can increase noise levels.
Sound pressure levels from motors, gear reducers, and belt driven units must be added.
11.3 Accessories
Couplings, sheaves, v-belts, guards, and baseplates may be provided.
11.4 Dimensions and Weights
For pump dimensions and weights, see General Arrangement Drawings.
11.5 Torque Values
METRIC Class 8.8 (N-m)
Bolt
Thread
Torque
Size
Pitch
6
1
10
8
1.25
14
10
1.5
23
12
1.75
54
14
2
80
16
2
108
18
2.5
128
20
2.5
162
22
2.5
216
24
3
270
27
3
324
30
3.5
378
33
3.5
432
36
4
486
SAE Grade 5 (Lb-Ft)
Bolt
Thread
Torque
Size
Pitch
1/4
20
7
5/16
18
10
3/8
16
17
1/2
13
40
5/8
8
80
3/4
7/8
1
1-1/8
1-1/4
1-3/8
1-1/2
7
7
6
10
11
9
9
120
160
200
240
280
320
360
Page 40
Rev 3
August 2014
12.0 TROUBLESHOOTING
Excessive wear on wetted parts
Pump surges
Loss of discharge pressure
Low capacity
Low discharge pressure
Pump loses prime
Excessive motor power draw
Stuffing box leakage
Reduced packing life
Excessive pump vibration or noise
Reduced bearing life
Pump overheats or seizes
Pump sump tank overflows
SYMPTOMS
POSSIBLE CAUSES
Pump not primed
Pump or suction pipe not completely filled with liquid
Suction lift too high
Insufficient NPSH
Air pocket in suction line
Air leaks in suction line
Air leaks into pump through stuffing box
Obstructed suction line
Suction pipe diameter too small or excessive friction losses in suction pipe
Suction head too high for expeller
Suction liquid velocity too high
Pump speed too low
Pump speed too high
Impeller running backwards
System head higher than design
System head lower than design
Material incompatible with liquid being pumped
Liquid specific gravity different from design
Unstable flow into pump sump tank
Low capacity operation
Entrained air in pump or frothy conditions
Improperly installed piping
Misalignment of motor to pump
Non-rigid foundation
Bent shaft
Rotating parts rubbing on stationary parts
Worn bearings
Worn or damaged impeller
Worn or scorned shaft sleeve
Improperly installed packing
Packing not suitable for operating conditions
Faulty mechanical seal
Excessive shaft runout
Unbalanced impeller
Packing gland too tight
Obstructed impeller hydraulic passage
Excessive thrust load
Excessive bearing lubrication
Insufficient bearing lubrication
Improperly installed bearings
Dirt in bearing housing
Moisture in bearing housing
Faulty bearing isolator
Worn expeller or excessive product buildup between expeller vanes
Excessive clearance between stuffing box and shaft sleeve
Loose pedestal clamp screws
Excessive V-belt tension
Page 41
Rev 3
August 2014
Appendix 1
Bearing Operating Temperature Range 63°C to 76°C (145°F to 170°F)
Pump
50 (2x2)
75 (3x3)
100 (4x3)
150 (6x4)
200 (8x6)
250 (10x8)
300 (12x10)
350 (14x12)
Lubrication Amount
Thrust
Radial
7 g (0.2 oz)
3g (0.1 oz)
11 g (0.4 oz) 4 g (0.1 oz)
15 g (0.5 oz) 6 g (0.2 oz)
23 g (0.8 oz) 8 g (0.3 oz)
32 g (1.1 oz) 13 g (0.5 oz)
40 g (1.4 oz) 17 g (0.6 oz)
60 g (2.1 oz) 21 g (0.8 oz)
71 g (2.5 oz) 29 g (1.0 oz)
Lubrication Interval Based On Pump Run Time
8 hrs/day
16 hrs/day
24 hrs/day
2300 hrs
1100 hrs
800 hrs
1500 hrs
700 hrs
500 hrs
1200 hrs
600 hrs
400 hrs
1700 hrs
900 hrs
600 hrs
2300 hrs
1100 hrs
800 hrs
2500 hrs
1300 hrs
800 hrs
2700 hrs
1300 hrs
900 hrs
3500 hrs
1800 hrs
1200 hrs
Pump
50 (2x2)
75 (3x3)
100 (4x3)
150 (6x4)
200 (8x6)
250 (10x8)
300 (12x10)
350 (14x12)
Lubrication Amount
Thrust
Radial
7 g (0.2 oz)
3g (0.1 oz)
11 g (0.4 oz) 4 g (0.1 oz)
15 g (0.5 oz) 6 g (0.2 oz)
23 g (0.8 oz) 8 g (0.3 oz)
32 g (1.1 oz) 13 g (0.5 oz)
40 g (1.4 oz) 17 g (0.6 oz)
60 g (2.1 oz) 21 g (0.8 oz)
71 g (2.5 oz) 29 g (1.0 oz)
8 hrs/day
16 hrs/day
24 hrs/day
1100 hrs
600 hrs
400 hrs
700 hrs
400 hrs
200 hrs
600 hrs
300 hrs
200 hrs
900 hrs
400 hrs
300 hrsd
1100 hrs
600 hrs
400 hrs
1300 hrs
600 hrs
400 hrs
1300 hrs
700 hrs
400 hrs
1800 hrs
900 hrs
600 hrs
Pump
50 (2x2)
75 (3x3)
100 (4x3)
150 (6x4)
200 (8x6)
250 (10x8)
300 (12x10)
350 (14x12)
Lubrication Amount
Thrust
Radial
7 g (0.2 oz)
3g (0.1 oz)
11 g (0.4 oz) 4 g (0.1 oz)
15 g (0.5 oz) 6 g (0.2 oz)
23 g (0.8 oz) 8 g (0.3 oz)
32 g (1.1 oz) 13 g (0.5 oz)
40 g (1.4 oz) 17 g (0.6 oz)
60 g (2.1 oz) 21 g (0.8 oz)
71 g (2.5 oz) 29 g (1.0 oz)
8 hrs/day
16 hrs/day
24 hrs/day
600 hrs
300 hrs
200 hrs
400 hrs
200 hrs
100 hrs
300 hrs
200 hrs
100 hrs
400 hrs
200 hrs
100 hrs
600 hrs
300 hrs
200 hrs
600 hrs
300 hrs
200 hrs
700 hrs
300 hrs
200 hrs
900 hrs
400 hrs
200 hrs
Page 42

EMW SLURRY PUMP - RUBBER - A.R. Wilfley and Sons, Inc.

Transcription

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